Absorbent article with captured leg elastics

ABSTRACT

An absorbent article having a leg elastic member captured between a biaxially extensible outer cover and a biaxially extensible bodyside liner.

CROSS REFERENCE TO RELATED APPLICATION

[0001] This application is a continuation-in-part application ofapplication, Ser. No. 09/698,517, filed on Oct. 27, 2000. The co-pendingparent application is hereby incorporated by reference herein and ismade a part hereof, including but not limited to those portions whichspecifically appear hereinafter.

FIELD OF THE INVENTION

[0002] This invention relates generally to absorbent articles forabsorbing body fluids and exudates.

[0003] One aspect of the present invention more particularly relates tosuch absorbent articles which desirably self-form seals at natural bodyhinge points of a wearer.

[0004] Another aspect of the present invention more particularly relatesto such absorbent articles which generally desirably provide improved orincreased independence of the components thereof.

[0005] Still another aspect of the present invention more particularlyrelates to such absorbent articles which include in-captured legelastics such as may desirably simplify manufacture and production andthe costs associated therewith.

BACKGROUND OF THE INVENTION

[0006] A wide variety of types of structures are known in the art foruse in or as absorbent articles, particularly disposable absorbentarticles, such as used to collect various body fluids and exudates. Inparticular, various commercial absorbent articles having a pant-likeform are known and/or available. For example, typical such commercialabsorbent articles include: adult incontinence garments, diapers forinfant and children, training pants and swim wear garments.

[0007] Disposable articles of these types generally comprise componentsfor receiving, absorbing and retaining fluids. Typically, the componentsof such articles include a liquid permeable topsheet, an absorbent coreand a liquid impermeable backsheet.

[0008] The human body is generally composed of a plurality of compound,as opposed to unidirectional, curves. The curves of the human body areparticularly complicated at locations where limbs, such as arms andlegs, join the torso. The curves can also be associated with hingepoints of the body. For example, the curves associated with where thelegs join the torso define hinge areas that are capable of moving inrelationship to each other. When an absorbent article is donned by awearer, the hinge areas (such as the leg and waist openings) are definedby compound curves—not straight lines. Hinge areas tend to be the areasof absorbent articles that are most susceptible to leakage. Conventionalabsorbent articles, however, are primarily rectangular in shape and thusprovide limited curvature in their components. Consequently,conventional absorbent articles are generally not optimal for providingclose-fitting seals between the edges of the absorbent article and theskin of the wearer. As a result, undesirable leakages may occur or beexperienced with the use of such absorbent articles. In an effort tocompensate for the lack of a close, custom fit and to provide desired orrequired skin coverage, conventional absorbent articles commonlyincorporate certain oversized components or elements, such asrectangular absorbent pads in the crotch region or area of the article.

[0009] Present day diapers commonly include stretchable side panels suchthat the garment is better able to conform to the contours of the bodyof the wearer. Other components of such present day articles, such asouter covers, bodyside liners and absorbent assemblies, for example,however, typically remain totally or at least primarily non-extensibleor unstretchable. As a result, when such a garment is worn, only theside panels can stretch.

[0010] In addition, such absorbent article garments and/or specificportions thereof are typically subjected to a wide range of stressessuch as may vary dependent on the size and movements of the wearer.Unfortunately, however, various conventional diapers do not allow orpermit these stresses to be relieved except by degradation of fit.Further, where the stresses are not appropriately relieved, the wearermay experience discomfort as well as red-marking of or on the skin ofthe wearer. As will be appreciated, fit degradation commonly results orproduces a concomitant degradation in the protection against leakageprovided by the diaper article. Further, when such conventional diapersdegrade with extended wear time, the side panels typically narrow suchas to concentrate forces along the sides at the fastening region of thediaper. The resulting high force loads on the fastening region of thediaper often leads to fastener failure, further or increased wearerdiscomfort, and/or further or increased red-marking of the skin of thewearer.

[0011] Also, as a result of a general inability for many diaper designsto adapt to differences in infant shapes, some conventional diapers aredifficult to apply onto an intended wearer. Further difficulty may beencountered by the tendency of a conventional diaper to fold back onitself or otherwise curl-up prior to application to an infant. Also,many conventional diapers do not hold the target area portions of theliner and absorbent desirably sufficiently close to the body, thusresulting in increased opportunity for bodily wastes to spread along theskin before such bodily wastes have been appropriately absorbed by or inthe diaper.

[0012] Further, it is common for diaper articles to include waistelastic members and leg elastic members, respectively, in an effort toenhance containment and/or absorption of body exudates. The outer coverand bodyside liner components of present day absorbent articles, such asdiapers, are generally not made of elastic or stretchable materials. Inmost commercial products, such leg elastics are captured between theouter cover and the liner which results in the outer cover and the linernecessarily being wider and longer than the torso measurements in orderto be capable of appropriately accommodating the stresses applied on thechassis when the product has been positioned in the crotch region of awearer. In addition, in such designs the leg elastics are well beyond(outboard) of the natural bodylines in the crotch region. Also, the legelastic can be placed in a curved orientation so as to conform to thecurved contour typically created by the absorbent article chassis toprovide a respective opening wherethrough a leg of the wearer may pass.

[0013] In view of the above, there is a need and a demand for improvedabsorbent articles.

[0014] In particular, there is a need and a demand for absorbentarticles, such as form-fitting, pant-like, personal care absorbentgarments, which desirably self-form seals at natural body hinge pointsof a wearer.

[0015] There is a further need and desire for such absorbent articleswhich generally desirably provide improved or increased independence ofthe components thereof.

[0016] There is a still further need and demand for such absorbentarticles which include in-captured leg elastics such as may desirablysimplify either or both manufacture and production and the costsassociated therewith.

SUMMARY OF THE INVENTION

[0017] A general object of the invention is to provide an improvedabsorbent article for absorbing body fluids and exudates.

[0018] A more specific objective of the invention is to overcome one ormore of the problems described above.

[0019] As detailed below, the general object of the invention cangenerally be attained through various specifically constructed absorbentarticles. Absorbent articles, in accordance with various embodiments ofthe invention, generally have or include a front waist area forming afront edge, a back waist area forming a back edge, and a crotch areadisposed between the front and back waist areas.

[0020] In accordance with one embodiment of the invention, the generalobject of the invention can be attained, at least in part, through aself-forming seal absorbent article adapted to be worn by a wearerhaving a body contour. Such an absorbent article includes a chassishaving opposed first and second longitudinal sides and opposed first andsecond lateral sides. The chassis also provides a footprint contouradapted to match the body contour of a wearer of the absorbent article.In accordance with one preferred embodiment, the chassis includes abiaxially extensible outer cover, a biaxially extensible bodyside linerforming a wearer adjacent surface, a biaxially extensible absorbent coreassembly interposed between the outer cover and the bodyside liner, anda pair of laterally-spaced apart and longitudinally-extendingcontainment flap members disposed along the wearer adjacent surface ofthe bodyside liner, each of the containment flap members comprises amaterial extensible in at least one of the longitudinal and lateraldirections.

[0021] In accordance with another embodiment of the invention, thegeneral object of the invention can be attained, at least in part,through an absorbent article which includes a chassis having opposedfirst and second longitudinal sides, opposed first and second lateralsides, an original longitudinal length, an original lateral length andwhich chassis has components including: an outer cover, a bodyside linerand an absorbent core assembly interposed between the outer cover andthe bodyside liner. In such an article of construction, the outer coverforms a cover perimeter and the bodyside liner forms a wearer adjacentsurface and a liner perimeter. Further, the chassis includes a perimeterarea and an interior area, wherein the perimeter area is defined atleast in part by the cover perimeter and the liner perimeter and whereinthe interior area is free of bonding.

[0022] In accordance with yet another embodiment of the invention, thegeneral object of the invention can be attained, at least in part,through an absorbent article which includes a chassis having opposedfirst and second longitudinal sides, opposed first and second lateralsides, an original longitudinal length, an original lateral length andwhich chassis defines first and second leg openings and includes: abiaxially extensible outer cover, a biaxially extensible bodyside linerforming a wearer adjacent surface, an absorbent core assembly interposedbetween the biaxially extensible outer cover and the biaxiallyextensible bodyside liner, a first leg elastic member captured betweenthe biaxially extensible outer cover and the biaxially extensiblebodyside liner along the first lateral side of the chassis and a secondleg elastic member captured between the biaxially extensible outer coverand the biaxially extensible bodyside liner along the second lateralside of the chassis.

[0023] The prior art generally fails to provide a design or constructionfor absorbent articles that desirably provides or results inform-fitting, pant-like, personal care absorbent garments, whichdesirably self-form seals at natural body hinge points of a wearer.Further, the prior art generally fails to provide a design orconstruction for absorbent articles that provide improved or increasedindependence of the components thereof to the extent desired in variousapplications. Still further, the prior art generally fails to provide adesign or construction for absorbent articles that desirably includein-captured leg elastics such as may desirably simplify either or bothmanufacture and production of the absorbent article and reduce the costsassociated therewith.

[0024] With the absorbent articles of the invention, the area of thearticle including all of the chassis components (e.g., outer cover,absorbent core and liner) is generally reduced. It is particularlydesirable to reduce the number of materials present in the areas of theleg and waist openings. The assembly of complete chassis materials canbe replaced with thinner and more pliable materials capable of curvingand conforming with the hinge areas. The seals formed by such materialstend not to form rugosities, bunching, folding, curling or otherdeformation of the material that can interfere with the article'sperformance. Self-forming seals can adjust to the shape of individualwearers.

[0025] The invention further comprehends a self-forming seal absorbentarticle such that includes a chassis having opposed first and secondlongitudinal sides and opposed first and second lateral sides. Thechassis also has an original longitudinal length and an original laterallength. The chassis further also provides a footprint contour adapted tomatch the body contour of a wearer of the absorbent article.

[0026] More particularly, such a chassis may desirably include: abiaxially stretchable outer cover, a biaxially stretchable bodysideliner forming a wearer adjacent surface, a biaxially stretchableabsorbent core assembly interposed between the outer cover and thebodyside liner, and a pair of laterally-spaced apart andlongitudinally-extending containment flap members disposed along thewearer adjacent surface of the bodyside liner, each of the containmentflap members being extensible in at least one of the longitudinal andlateral directions. In accordance with a particularly preferredembodiment of the invention, such a chassis can be longitudinallystretched at least 5 percent and up to 150 percent of its originallongitudinal length and laterally stretched at least 10 percent and upto 200 percent of its original lateral length.

[0027] The invention also comprehends an absorbent article such asadapted to be worn by a wearer and which absorbent article includes afront waist area forming a front edge, a back waist area forming a backedge, and a crotch area disposed between the front and back waist areas.The absorbent article also includes a chassis. The chassis has opposedfirst and second longitudinal sides and opposed first and second lateralsides. The chassis also has an original longitudinal length and anoriginal lateral length. The chassis further comprises componentsincluding; an outer cover forming a cover perimeter, a bodyside linerforming a wearer adjacent surface and a liner perimeter, and anabsorbent core assembly interposed between the outer cover and thebodyside liner. The chassis includes a perimeter area and an interiorarea, wherein the perimeter area is defined at least in part by thecover perimeter and the liner perimeter and wherein the interior area isfree of bonding.

[0028] The invention further comprehends a self-forming seal absorbentarticle adapted to be worn by a wearer having a body contour and whichabsorbent article including a front waist area forming a front edge, aback waist area forming a back edge, and a crotch area disposed betweenthe front and back waist areas. The absorbent article includes a chassishaving opposed first and second longitudinal sides and opposed first andsecond lateral sides. The chassis also provides a footprint contouradapted to match the body contour of a wearer of the absorbent article.The chassis includes a biaxially extensible outer cover, a biaxiallyextensible bodyside liner forming a wearer adjacent surface, a biaxiallyextensible absorbent core assembly interposed between the outer coverand the bodyside liner, and a pair of laterally-spaced apart andlongitudinally-extending containment flap members disposed along thewearer adjacent surface of the bodyside liner, each of the containmentflap members comprises a material extensible in at least one of thelongitudinal and lateral directions. The chassis includes a perimeterarea and an interior area, wherein the perimeter area is defined atleast in part by the cover perimeter and the liner perimeter and whereinthe interior area is free of bonding.

[0029] The invention still further comprehends a self-forming sealabsorbent article adapted to be worn by a wearer having a body contour.The absorbent article includes a front waist area forming a front edge,a back waist area forming a back edge, and a crotch area disposedbetween the front and back waist areas. The absorbent article furtherincludes a biaxially stretchable chassis having opposed first and secondlongitudinal sides and opposed first and second lateral sides. Thechassis has an original longitudinal length and an original laterallength. The chassis also provides a footprint contour adapted to matchthe body contour of a wearer of the absorbent article. The chassisincludes: a biaxially stretchable outer cover, a biaxially stretchablebodyside liner forming a wearer adjacent surface, a biaxiallystretchable absorbent core assembly interposed between the outer coverand the bodyside liner, and a pair of laterally-spaced apart andlongitudinally-extending containment flap members disposed along thewearer adjacent surface of the bodyside liner, each of the containmentflap members being extensible in at least one of the longitudinal andlateral directions. The further includes a perimeter area and aninterior area, wherein the perimeter area is defined at least in part bythe cover perimeter and the liner perimeter and wherein the interiorarea is free of bonding. Further, the chassis can be longitudinallystretched at least 5 percent and up to 150 percent of its originallongitudinal length and laterally stretched at least 10 percent and upto 200 percent of its original lateral length.

[0030] The invention additionally comprehends an absorbent articleadapted to be worn by a wearer and which absorbent article has a frontwaist area forming a front edge, a back waist area forming a back edge,and a crotch area disposed between the front and back waist areas. Theabsorbent article also includes a chassis having opposed first andsecond longitudinal sides and opposed first and second lateral sides.The chassis has an original longitudinal length and an original laterallength. The chassis defines first and second leg openings. The chassisincludes: a biaxially extensible outer cover, a biaxially extensiblebodyside liner forming a wearer adjacent surface, an absorbent coreassembly interposed between the biaxially extensible outer cover and thebiaxially extensible bodyside liner, a first leg elastic member capturedbetween the biaxially extensible outer cover and the biaxiallyextensible bodyside liner along the first longitudinal side of thechassis and a second leg elastic member captured between the biaxiallyextensible outer cover and the biaxially extensible bodyside liner alongthe second longitudinal side of the chassis.

[0031] The invention additionally further comprehends such an absorbentarticle wherein each of the first and second longitudinal sides forms astraight edge and wherein at least one of the first and second legelastic members comprises an elastic film material.

[0032] As used herein,“extensible” and the like refer to that propertyof a material, member, element or composite by virtue of which it tendsto be extended beyond its original size and shape upon application of aforce causing a deformation.

[0033] Further, “stretchable” and the like refer to that property of amaterial, member, element or composite by virtue of which it tends torecover its original size and shape after removal of a force causing adeformation. In connection therewith, “elastic ,” “elasticized,”“elasticity” and the like also generally refer to that property of amaterial, member, element or composite by virtue of which it tends torecover its original size and shape after removal of a force causing adeformation.

[0034] “Biaxial extensibility” refers to a material having extensibilityin two directions perpendicular to one another, e.g., extensibility in amachine direction and in a cross direction, or in a longitudinaldirection (front to back) and a lateral direction (side to side).

[0035] “Biaxial stretch” refers to a material having stretchability intwo directions perpendicular to one another, e.g., stretchability in amachine direction and in a cross direction, or in a longitudinaldirection (front to back) and a lateral direction (side to side).

[0036] “Bonded” refers to the joining, adhering, connecting, attaching,or the like, of two elements. Two elements will be considered to bebonded together when they are bonded directly to one another orindirectly to one another, such as when each is directly bonded tointermediate elements.

[0037] “Layer,” when used herein in the singular, can have the dualmeaning of a single element or a plurality of elements.

[0038] “Longitudinal” and “lateral” have their customary meaning, asindicated by the longitudinal and lateral axes depicted in FIG. 2. Thelongitudinal axis lies in the plane of the article and is generallyparallel to a vertical plane that bisects a standing wearer into leftand right body halves when the article is worn. The lateral axis lies inthe plane of the article generally perpendicular to the longitudinalaxis. The article as illustrated is longer in the longitudinal directionthan in the lateral direction.

[0039] “Longitudinal extensibility” refers to extensibility in thelongitudinal direction along the longitudinal axis.

[0040] “Longitudinal stretch” refers to stretchability in thelongitudinal direction along the longitudinal axis.

[0041] “Meltblown fiber” means fibers formed by extruding a moltenthermoplastic material through a plurality of fine, usually circular,die capillaries as molten threads or filaments into converging highvelocity heated gas (e.g., air) streams which attenuate the filaments ofmolten thermoplastic material to reduce their diameter, which may be tomicrofiber diameter. Thereafter, the meltblown fibers are carried by thehigh velocity gas stream and are deposited on a collecting surface toform a web of randomly dispersed meltblown fibers. Such a process isdisclosed for example, in U.S. Pat. No. 3,849,241 to Butin et al.Meltblown fibers are microfibers which may be continuous ordiscontinuous, are generally smaller than about 0.6 decitex, and aregenerally self-bonding when deposited onto a collecting surface.Meltblown fibers used in the present invention are preferablysubstantially continuous in length.

[0042] “Microfibers” are small diameter fibers typically having anaverage fiber denier of about 0.005-10. Fiber denier is defined as gramsper 9000 meters of a fiber. For a fiber having circular cross-section,denier may be calculated as fiber diameter in microns squared,multiplied by the density in grams/cc, multiplied by 0.00707. For fibersmade of the same polymer, a lower denier indicates a finer fiber and ahigher denier indicates a thicker or heavier fiber. For example, thediameter of a polypropylene fiber given as 15 microns may be convertedto denier by squaring, multiplying the result by 0.89 g/cc andmultiplying by 0.00707. Thus, a 15 micron polypropylene fiber has adenier of about 1.42 calculated as (15²×0.89×0.00707=1.415). Outside theUnited States the unit of measurement is more commonly the “tex,” whichis defined as the grams per kilometer of fiber. Tex may be calculated asdenier/9. A decitex is 0.1 of a tex.

[0043] “Necked” or “neck-stretched” interchangeably refer to a method ofelongating a nonwoven fabric, generally in the longitudinal, or machinedirection, to reduce its width in a controlled manner to a desiredamount. The controlled stretching may take place under cool, roomtemperature or greater temperatures and is limited to an increase inoverall dimension in the direction being stretched up to the elongationrequired to break the fabric, which in most cases is about 1.2 to 1.4times. When relaxed, the web retracts toward its original dimensions.Such a process is disclosed, for example, in U.S. Pat. Nos. 4,443,513 toMeitner and Notheis, 4,965,122, 4,981,747 and 5,114,781 to Morman and5,244,482 to Hassenboehler Jr. et al.

[0044] “Nonwoven” and “nonwoven web” refer to fibrous materials and websof fibrous material which are formed without the aid of a textileweaving or knitting process.

[0045] “Superabsorbent” or “superabsorbent material” refers to awater-swellable, water-insoluble organic or inorganic material capable,under the most favorable conditions, of absorbing at least about 15times its weight and, more desirably, at least about 30 times its weightin an aqueous solution containing 0.9 weight percent sodium chloride.The superabsorbent materials can be natural, synthetic and modifiednatural polymers and materials. In addition, the superabsorbentmaterials can be inorganic materials, such as silica gels, or organiccompounds such as cross-linked polymers.

[0046] “Surface” includes any layer, film, woven, nonwoven, laminate,composite, or the like, whether pervious or impervious to air, gas,and/or liquids.

[0047] “Thermoplastic” describes a polymer material that softens andflows when exposed to sufficient heat and which substantially returns toa nonsoftened condition when cooled to room temperature.

[0048] Other objects and advantages will be apparent to those skilled inthe art from the following detailed description taken in conjunctionwith the appended claims and drawings.

BRIEF DESCRIPTION OF THE DRAWINGS

[0049]FIG. 1 is a side perspective view of an absorbent garment article,in accordance with one preferred embodiment of the invention, in afastened position.

[0050]FIG. 2 is a simplified plan schematic view of the absorbentgarment article shown in FIG. 1 and showing the surface of the articlethat faces the wearer when the article is worn.

[0051]FIG. 3 is a simplified plan view of the footprint contour of thechassis of the absorbent garment article, shown in FIGS. 1 and 2, shownin isolation.

[0052]FIG. 4 is a schematic plan view of an absorbent assembly suitablefor use in the absorbent garment article shown in FIGS. 1 and 2.

[0053]FIG. 5 is a simplified schematic plan view showing absorbentassembly seals in accordance with one preferred embodiment of theinvention.

[0054]FIG. 6 is a simplified schematic plan view showing chassisperimeter seals for an absorbent garment article in accordance with onepreferred embodiment of the invention.

[0055]FIG. 7 is a simplified schematic plan view showing chassisperimeter seals for an absorbent garment article in accordance withanother preferred embodiment of the invention.

[0056]FIG. 8 is a simplified schematic plan view showing chassisperimeter seals for an absorbent garment article including containmentflaps, in accordance with one embodiment of the invention.

[0057]FIG. 9 is a simplified plan schematic view, similar to the viewshown in FIG. 2, but now showing an absorbent garment article inaccordance with another preferred embodiment of the invention.

[0058]FIG. 10 is a simplified plan schematic view of the absorbentgarment article shown in FIG. 9 and now showing the surface of thearticle that faces away from the wearer when the article is worn.

[0059]FIG. 11 is a simplified frontal perspective view of the absorbentgarment article shown in FIGS. 1 and 2 as it is applied to the torso ofa wearer.

[0060]FIG. 12 is a corresponding simplified frontal perspective view ofa prior art absorbent garment article which makes use of straight legelastics as it is applied to the torso of a wearer.

[0061]FIG. 13 is a simplified side perspective view of the absorbentgarment article shown in FIG. 11 as it is applied to the torso of awearer.

[0062]FIG. 14 is a corresponding simplified side perspective view of theprior art absorbent garment article shown in FIG. 12 as applied to thetorso of a wearer.

[0063]FIG. 15 is a simplified side perspective view of the absorbentgarment article shown in FIG. 11 as it is applied to the torso of awearer and showing the inner containment flap.

[0064]FIG. 16 is a corresponding simplified side perspective view of theprior art absorbent garment article shown in FIG. 12 as applied to thetorso of a wearer and showing the inner containment flap thereof.

[0065]FIG. 17 is a simplified side perspective view of the absorbentgarment article shown in FIG. 11 as it is applied to the torso of awearer and showing the leg seal formed thereby.

[0066]FIG. 18 is a corresponding simplified side perspective view of theprior art absorbent garment article shown in FIG. 12 as applied to thetorso of a wearer and showing the leg seal formed thereby.

[0067]FIG. 19 is a simplified back perspective view of the absorbentgarment article shown in FIG. 11 as it is applied to the torso of awearer.

[0068]FIG. 20 is a corresponding simplified back perspective view of aprior art absorbent garment article as it is applied to the torso of awearer.

[0069] FIGS. 21-25 are simplified front, side, side showing the innercontainment flap, side showing the leg seal formed thereby and backperspective view of the absorbent garment article shown in FIGS. 1 and 2and generally corresponding to FIGS. 11, 13, 15, 17 and 19 but nowshowing the absorbent garment article after loading, e.g., 120 ml ofliquid, and wear.

[0070]FIG. 26A is a line drawing showing the body profile of thediapering area for an average infant weighing 16-28 pounds (7-13 kg) ina sitting position.

[0071]FIG. 26B is a line drawing showing the body profile of thediapering area for an average infant weighing 16-28 pounds (7-13 kg) ina standing position.

[0072]FIG. 27 is a simplified plan schematic view of the absorbentgarment article shown in FIG. 1 and generally similar to FIG. 2 and hereincluded to facilitate comparison relative to FIGS. 26A and 26B.

DETAILED DESCRIPTION OF THE INVENTION

[0073] The present invention, as is described in more detail below,provides an improved absorbent article for absorbing body fluids andexudates. In particular, absorbent article configurations andconstructions in accordance with the invention desirably provideimprovements with respect to at least one, preferably at least two and,more preferably all three of the absorbent article qualities orproperties of fit, comfort and containment capability for body fluidsand exudates. As detailed below, absorbent articles, in accordance withat least certain preferred embodiments of the invention, involve theselection and use of certain specified materials in certain specificabsorbent article constructions.

[0074] In accordance with one aspect of the invention, absorbentarticles, such as form-fitting, pant-like, personal care absorbentgarments, which desirably self-form seals between the absorbent article,e.g., the edges thereof, and the skin of the wearer, at natural bodyhinge points of a wearer are provided. In accordance with another aspectof the invention, there are provided absorbent articles which generallydesirably provide or result in improved or increased independence of thecomponents in order to improve the fit of the articles. In accordancewith another aspect of the invention there are provided absorbentarticles of specific construction and which include captured legelastics that improve the garment-like fit at the leg and providetargeted stretch and recovery in multiple directions without a highdegree of pre-tension and recovery. Captured leg elastics may alsodesirably simplify either or both manufacture and production and thecosts associated therewith.

[0075] Referring initially to FIGS. 1 and 2, there is illustrated adisposable absorbent article, in accordance with one preferredembodiment of the invention and generally designated by the referencenumeral 20. FIG. 1 illustrates the absorbent garment article 20 in afastened position. FIG. 2 illustrates the absorbent garment article 20in a simplified plan schematic view, showing the surface of the articlethat faces the wearer when the article is worn. As will be appreciated,the absorbent article 20 has the general form of a disposable diapersuch as adapted to be worn about the lower torso by an infant. It is tobe understood, however, that while the invention is described below withparticular reference to disposable diapers such as for an infant or achild, the broader practice of the invention is not necessarily solimited. For example, the invention can, if desired, be applied to otherforms or types of absorbent articles including various disposableabsorbent articles such as are generally configured to collect andcontain human discharges or exudates such as, including, urine and fecalmaterial and which articles also desirably avoid leakage of suchdischarge materials. Other examples of such suitable articles includeadult incontinence garments, training pants and swim wear garments aswell as other personal care or health care garments, or the like.

[0076] The diaper absorbent article 20 generally includes a chassis 22and further includes or defines a front waist area or region 24 forminga front edge 26, a back waist area or region 30 forming a back edge 32,and a crotch area or region 34 disposed between the front and back waistareas, 24 and 30, respectively. The waist area 24 includes the portionof the diaper 20 which, when worn, is positioned on the front of thewearer while the back waist area 30 includes the portion of the diaperwhich, when worn, is positioned on the back of the wearer. The crotchregion 34 includes that portion of the diaper 20 which, when worn, ispositioned between the legs of the wearer and covers the lower torso ofthe wearer. The diaper absorbent article 20 forms or includes an innersurface 36 which is configured to contact the wearer, and an outersurface 40 opposite the inner surface 36 and such as configured tocontact the wearer's clothing.

[0077]FIG. 3 illustrates the general footprint contour 44 of theabsorbent chassis 22, shown in isolation with the front waist area 24,back waist area 30 and crotch area 34 accordingly designated. As shown,such footprint contour generally corresponds to the outline formed bythe chassis without the inclusion of fastener flaps and the like. Theabsorbent chassis 22 is generally conformable and capable of absorbingor otherwise appropriately retaining body exudates. In general, the sizeand absorbent capacity of the absorbent chassis 22 are selected forcompatibility with the size of the intended wearer and the fluid loadingimparted by the intended use of the absorbent article 20. In accordancewith the one preferred embodiment of the invention, the footprintcontour 44 is, as shown, adapted to match the body contour of theprojected or anticipated wearer of the absorbent article. To that end,it is generally preferred that absorbent chassis used in the practice ofthe invention be narrower in the crotch area 34 as compared to the frontwaist and back waist areas, 34 and 30, respectively. It has been foundthat absorbent chassis for use in the practice of the invention areparticularly useful when the width dimension in the crotch area 34 isfrom about 2.5 to about 10.2 centimeters (from about 1 to about 4inches), preferably having a crotch area width of no more than about 7.6centimeters (3 inches) and, more preferably, having a crotch area widthof no more than about 5.1 centimeters (2 inches). Such crotch widthdimensions for absorbent articles and chassis in accordance with theinvention have been found to generally result in a better fit of theabsorbent article on a wearer, particularly between the legs of thewearer.

[0078] To more fully appreciate the invention, reference is now made toFIG. 26A and FIG. 26B which are line drawings showing the body profileof the diapering area for an average infant weighing 16-28 pounds (7-13kg) in a sitting position and in a standing position, respectively, andFIG. 27 which is a simplified plan schematic view of the absorbentgarment article shown in FIG. 1 and generally similar to FIG. 2. Asshown, absorbent garment articles in accordance with the inventiondesirably have or provide a contour which closely matches that of thebody of a wearer. Various of the advantages resulting or relatingthereto are more fully described and detailed elsewhere herein.

[0079] Returning to FIG. 2, for ease of reference there are includedarrows 50 and 52 depicting the orientation of the longitudinal and thelateral or transverse axis, respectively, for the diaper absorbentarticle 20. Thus, as shown in FIG. 2, the chassis 22 has opposedlongitudinal sides 54 and 56, respectively, and opposed lateral sides 60and 62, respectively.

[0080] As will be appreciated, the absorbent chassis 22 is desirablygenerally configured to contain and/or absorb body exudates dischargedfrom the wearer. To that end and as shown in FIGS. 1 and 2, the diaper20 and, specifically, the chassis 22 includes an outer cover 64 such asserves, at least in part, to form the outer surface 40, and a bodysideliner 66 such as serves, at least in part, to form the inner or weareradjacent surface 36. The outer cover 64 forms or includes a coverperimeter 67. The bodyside liner 66 similarly forms or includes a linerperimeter 68. The outer cover 64 and the bodyside liner 66 are joined orconnected, such as described in greater detail below, in a superposedrelation. An absorbent core assembly 70, such as shown in FIG. 4 and asdescribed in greater detail below, is interposed or otherwise locatedbetween the outer cover 64 and the bodyside liner 66.

[0081] Further, in accordance with a preferred embodiment of theinvention, the diaper 20 and, specifically, the chassis 22 includes apair of laterally-spaced apart and longitudinally-extending containmentflap or gasket members, 72 and 74, respectively, such as disposed alongthe wearer adjacent surface 36 of the bodyside liner 66 and which areconfigured to provide a barrier to the transverse or lateral flow ofbody exudates. The containment flap members 72 and 74 each generallydefine an unattached edge which assumes an upright, generallyperpendicular configuration in at least the crotch area 34 of the diaper20 to form a seal against the wearer's body. Containment flap memberconstructions and arrangements are generally well known to those skilledin the art and are described in U.S. Pat. No. 4,704,116 issued Nov. 3,1987 to Enloe, which is incorporated herein by reference.

[0082] The diaper absorbent article 20 further includes a pair ofoppositely disposed leg extended elements 76 and 78, respectively,continuous with or otherwise generally laterally extending from eitheror both the outer cover 64 and the bodyside liner 66 of the chassis 22at the longitudinal sides 54 and 56, respectively, thereof. In such adiaper absorbent element configuration, the leg cuff elements 76 and 78desirably serve as leg elastic elements which outwardly extend from theabsorbent core of the diaper article 20. While the invention can bepracticed with absorbent articles which include such leg cuff elements,the invention can, if desired, alternatively incorporate and employ anencased or captured leg elastic such as described in greater detailbelow.

[0083] As shown in the diaper 20 in FIG. 1, the crotch area 34 and frontand back waist areas 24 and 30 together define a three-dimensional pantconfiguration having a waist opening 80 and a pair of leg openings 82.The waist edges 26 and 32 are configured to encircle the waist of awearer when worn and provide the waist opening 80 which defines a waistperimeter dimension.

[0084] To further enhance containment and/or absorption of bodyexudates, the diaper 20 can include waist elastic members 84, as areknown to those skilled in the art. The waist elastic members 84 can beoperatively joined to the outer cover 64 and/or the bodyside liner 66,and can extend over part or all of the waist edges 26 and 32.

[0085] The diaper 20 also includes a fastening system 86, such as knownin the art and such as operatively attached to the outer cover 64 alongthe longitudinally extending sides 54 and 56, just below the waist edges32 and 26. As shown, the fastening system 86 can include a pair oflaterally-opposed back fastener tabs 88 that can be fastened directly tothe front waist area or region 24 of the absorbent article 20, as shownin FIG. 1, by suitable means, such as mechanical fasteners, for example.As will be appreciated, other fastener systems or means can, if desired,be used in the practice of the invention and thus the broader practiceof the invention is to be understood as not limited by or to theincorporation or use of specific fastening systems or techniques. Thediaper 20 also includes front flaps or ears 90 such as known in the artand such as may be desired for various reasons such as to better provideor ensure a snug fit of the diaper article onto the torso of a wearer,for example.

[0086] In accordance with one aspect of the invention, a chassis whichprovides a footprint contour adapted to match the body contour of awearer of the absorbent article (as shown in FIGS. 26A and 26B) isdesirably combined with specifically selected materials of constructionand article configuration to provide or result in an article thatself-forms seals at natural body hinge points of a wearer. In onepreferred embodiment of the invention, the outer cover 64, the bodysideliner 66 and the absorbent core assembly 70 are each formed of materialsor constructed to be biaxially extensible and each of the containmentflap members 72 and 74 comprises a material extensible in at least oneof the longitudinal and lateral directions.

[0087] Returning to FIG. 3, the general footprint contour 44 is shownwith longitudinal, lateral and diagonal directions designated by thereference numerals 91, 92 and 93, respectively. While the invention candesirably be practiced to produce absorbent articles which self-formseals wherein the chassis provides various selected degrees ofextensibility and, in at least certain preferred embodimentsstretchability, absorbent articles wherein the chassis can be extendedin the longitudinal direction 91 at least 5 percent and up to 150percent of its original longitudinal length are generally preferred;with absorbent articles wherein the chassis can be extended in thelongitudinal direction 91 at least 15 percent and up to 125 percent ofits original longitudinal length generally being more preferred; andwith absorbent articles wherein the chassis can be extended in thelongitudinal direction 91 at least 30 percent and up to 100 percent ofits original longitudinal length generally being most preferred.Correspondingly, absorbent articles wherein the chassis can be extendedin the lateral direction 92 at least 10 percent and up to 200 percent ofits original lateral length are generally preferred, with absorbentarticles wherein the chassis can be extended in the lateral direction 92at least 25 percent and up to 150 percent of its original lateral lengthgenerally being more preferred, and with absorbent articles wherein thechassis can be extended in the lateral direction 92 at least 50 percentand up to 125 percent of its original lateral length generally beingmost preferred. Further, absorbent articles wherein the chassis can beextended in the diagonal direction 93 at least 10 percent and up to 200percent of its original diagonal length are generally preferred; withabsorbent articles wherein the chassis can be extended in the diagonaldirection 93 at least 25 percent and up to 150 percent of its originaldiagonal length generally being more preferred; and with absorbentarticles wherein the chassis can be extended in the diagonal direction93 at least 50 percent and up to 125 percent of its original diagonallength being most preferred. Absorbent articles with such extensibilityare in sharp contrast to current absorbent articles which have anon-extensible chassis, e.g., have a chassis which can be extended a) inthe longitudinal direction only about 5 percent of its originallongitudinal length, b) in the lateral direction only about 5 percent ofits original lateral length, and c) in the diagonal direction only about1 percent of its original diagonal length.

[0088] Further, in accordance with certain preferred embodiments, one ormore and, in certain cases, each of the outer cover 64, the bodysideliner 66 and the absorbent core assembly 70 can be formed of materialsor constructed to be biaxially stretchable. For example, in certainpreferred embodiments absorbent articles in accordance with theinvention desirably have longitudinal, lateral and diagonalstretchabilities that generally correspond to the extendibilities setforth above.

[0089] Still further, in accordance with certain preferred embodiments,each of the pair of containment flap members 72 and 74 desirablycomprises a material extensible in both the longitudinal and lateraldirections.

[0090] Yet still further, in accordance with certain preferredembodiments, each of the pair of containment flap members 72 and 74desirably comprises a biaxially stretchable material.

[0091] Suitable materials for the biaxially extensible outer cover 64include biaxially extensible materials and biaxially elastic stretchablematerials. One example of a suitable outer cover material for use in thepractice of the invention is composed of 0.3 ounces per square yard(osy) polypropylene spunbond, necked and creped at about 50% and that islaminated with 3 grams per square meter (gsm) Findley 2525Astyrene-isoprene-styrene-based adhesive to 10 gsm PEBAX® 2533 film andsuch as provides a longitudinal and lateral elongation optimum ofbetween 100%-200% and a tension at 50% extension preferably between50-600 g, with an optimum of between 100-400 g, as measured on 3-inchwide material.

[0092] Suitable materials for the biaxially extensible bodyside liner 66include biaxially extensible materials and biaxially elastic stretchablematerials. One example of a suitable bodyside liner material for use inthe practice of the invention is composed of 0.3 osy polypropylenespunbond, necked and creped at about 50% and treated with about 0.7weight percent of a surfactant such as AHCOVEL® from Hodgson TextileChemicals of Mount Holly, N.C., U.S.

[0093] Suitable materials for the containment flap members 72 and 74include materials extensible in at least one of the longitudinal andlateral directions, materials stretchable in at least one of thelongitudinal and lateral directions, materials which are biaxiallyextensible and materials which are biaxially elastic stretchable. Anexample of a suitable containment flap material is polypropylenespunbond necked and creped at about 50% with Findley HX 2695 ElasticBarrier Adhesive strands or slot coated.

[0094] For those embodiments which incorporate a leg cuff, a suitablematerial of construction for the leg cuffs 76 and 78 which, as describedabove, generally refers to such wearer leg adjacent portion whichextends beyond the cover outer edge, is an Elastic Barrier Adhesive suchas constituting 110 gsm Findley HX 2695 adhesive at 750% elongation with0.6 osy prism facings on both sides. Suitable encased leg elasticmaterials for use in alternative embodiments of the invention candesirably constitute such an Elastic Barrier Adhesive without thefacings. Waist elastics used in the absorbent articles of the inventionmay also be formed of such materials. In addition, low tension spandexfibers sold under the trade name LYCRA® available from E. I. du Pont deNemours and Company, Wilmington, Del., U.S., may be used as a suitableleg and/or waist elastic.

[0095] The waist elastic members 84 used in the practice of theinvention can be formed of any suitable elastic material. As is wellknown to those skilled in the art, suitable elastic materials includesheets, strands or ribbons of natural rubber, synthetic rubber, orthermoplastic elastomeric polymers. The elastic materials can bestretched and adhered to a substrate, adhered to a gathered substrate,or adhered to a substrate and then elasticized or shrunk, for examplewith the application of heat; such that elastic constrictive forces areimparted to the substrate. In one particular embodiment, for example,the waist elastic members 84 include a plurality of dry-spun coalescedmultifilament spandex elastomeric threads sold under the trade nameLYCRA®. In another particular embodiment, for example, the waist elasticmembers 84 include Findley HX 2695-01 adhesive laminated to two facingsof 0.6 osy bicomponent polypropylene/polyethylene spunbond.Alternatively, up to about six strands of 310 decitex LYCRA® may be alsolaminated at 250% elongation between the spunbond facings in addition tothe Findley adhesive.

[0096]FIG. 4 is a schematic plan view of the absorbent core assembly 70,in accordance with one embodiment of the invention and suitable for usein the absorbent garment article shown in FIGS. 1 and 2. As identifiedabove, the absorbent core assembly 70 is desirably formed of materialsor otherwise constructed to be biaxially extensible. Further, inaccordance with certain preferred embodiments of the invention, theabsorbent core assembly is desirably formed of materials or otherwiseconstructed to be biaxially and diagonally stretchable. Those skilled inthe art and guided by the teachings herein provided will appreciate thatabsorbents or absorbent core assemblies used in the practice of theinvention need not necessarily be stretchable. For example, inaccordance with certain embodiments, the absorbent or absorbent coreassembly can be: (1) non-extensible; (2) machine direction (MD)extensible; (3) cross direction (CD) extensible; or (4) biaxiallyextensible.

[0097] The absorbent core assembly 70 includes a carrier layer 94, afull pad continuous layer 96, and a notched absorbent core 100. In theillustrated embodiment, the carrier layer 94 extends beyond theabsorbent region of the assembly 70 to form either or both front andback tails 104 and 106, respectively. The tails 104 and 106 are joinedor attached to the respective front and back waist edges 26 and 32, ofthe bodyside liner 66 and the outer cover 64, respectively (shown inFIGS. 1 and 2). The tails 104 and 106 are generally extensions of orextending from the carrier layer 94 and are transversely discontinuous,such that when bonded to a biaxially stretchable bodyside liner 66and/or biaxially stretchable outer cover 64, the transverse stretch ofthe bodyside liner 66 and/or outer cover 64 are not hindered by any lackof transverse stretchability by the material constituting the carrierlayer 94.

[0098] It has been found that through the inclusion or incorporation ofnotches in a desired number and pattern or arrangement, absorbent coreassembly components which might not otherwise provide or result indesired product stretchability or extensibility can be produced orformed to satisfy such product design capabilities. Thus, in theillustrated embodiment shown in FIG. 4, the full pad continuous layer 96is composed of a stretch coform which has notches 108 formed on thesides and the middle. The notched absorbent core 100 can be suitablyformed of a superabsorbent material meltblown with 10% pulp Pledgetwhich has notches 110 located only along the sides thereof.

[0099] Those skilled in the art and guided by the teachings hereinprovided will appreciate that other suitable means or techniques toprovide stretchability or extensibility to product components, such asthe absorbent core assembly, can be used if desired and withoutdeparting from the practice of the invention. For example, the inventioncan, if desired, be practiced employing segmented absorbent materialssuch as disclosed in parent patent application, U.S. Ser. No.09/698,517, filed on Oct. 27, 2000.

[0100] While the broader practice of the invention is not necessarilylimited by the manner or means by which such components of suchabsorbent core assembly are fastened or otherwise joined to form theassembly, in accordance with a preferred practice of the invention it isdesirable to avoid or minimize the joinder or attachments of componentsor elements such that the components may more freely and independentlymove relative to each. To that end, FIG. 5 illustrates the absorbentcore assembly 70 incorporating ultra sonic point bond seals 120 aboutthe perimeter 122 thereof, in accordance with one preferred embodimentof the invention. In accordance with a preferred practice of theinvention, bonding or attachment within the interior region 124 isminimized or preferably avoided.

[0101] Point bonding is well known to those skilled in the art. Pointbonding permits materials to extend or stretch between adjacent bondpoints and thus is a preferred bonding technique for use in the practiceof the invention.

[0102] While application of such sonic bonding techniques is currentlypreferred, it will be appreciated that other bonding or joindertechniques can also be used. For example, bonding via an adhesivematerial can be used. Again, such bonding is preferably concentratedabout the perimeter of the assembly and bonding or attachment within theinterior region is minimized or preferably avoided. In those absorbentarticles in accordance with the invention which include or rely on suchadhesive bonding, an adhesive having elastic properties, such as FindleyHX 2695-01 adhesive, may be used.

[0103] Individual layers or components of an absorbent article, inaccordance with a preferred practice of the invention, are preferablyminimally attached to other layers or components such as to increase ormaximize the freedom of movement of such layers or components relativeto each other.

[0104] As identified above, the outer cover 64 and the bodyside liner 66of absorbent articles 20 in accordance with the invention are generallyjoined or connected in a superposed relation. FIG. 6 is a schematic planview showing component bonding or attachment, in accordance with onepreferred embodiment of the invention, in the absorbent garment article20 described above but now simplified by not showing the containmentflap members 72 and 74 in an effort to simplify illustration andfacilitate comprehension. Bonding or attachment of such containment flapmembers is described in detail below making reference to FIG. 8.

[0105]FIG. 6 shows bonding or attachment of the components in theabsorbent garment article 20 such as to desirably provide improved orincreased independence of the components thereof, in accordance with onepreferred embodiment of the invention. In particular, the chassis 22includes a perimeter area 130 and an interior area 132, wherein theperimeter area 130 is defined at least in part by the cover perimeter 67and the liner perimeter 68, described and identified above. Inaccordance with one preferred embodiment of the invention, the interiorarea 132 is desirably free of bonding. In particular, chassis componentsare bonded only in the perimeter area 130. As identified above, apreferred bonding technique or method is ultra sonic point bonding. FIG.6 illustrates a plurality of ultra sonic point bond seals 134 about thechassis perimeter area 130 to bond or join the various components whichcomprise the absorbent article. Thus, in accordance with one preferredembodiment of the invention and with bonding or attachment within theinterior area 132 is minimized or preferably avoided. As discussedabove, such point bonding desirably permits materials to extend orstretch between adjacent bond points.

[0106]FIG. 7 is a simplified schematic plan view showing componentbonding or attachment in accordance with an alternative embodiment ofthe invention relative to an absorbent garment article herein designatedby the reference numeral 140. The absorbent garment article 140 isgenerally otherwise similar to the absorbent garment article 20described above and, as in FIG. 6, simplified by not showing thecontainment flap members.

[0107] In the absorbent garment article 140, the interior area 142 againpreferably includes minimal bonding or attachment between componentsand, in accordance with a preferred embodiment, is free of bonding.Bonding or attachment by and between components in this embodiment isaccomplished through a combination of ultra sonic bonds 144 and elasticadhesive bonding 146, such as discussed and described above. Inparticular, both the ultra sonic bonds 144 and the elastic adhesivebonding 146 occur in the perimeter area 148 of the article 140.

[0108] Similar to the absorbent core assembly attachment or bondingdescribed above relative to FIG. 5, if the application of adhesivebonding techniques are desired or required in a particular applicationit is generally preferred that the adhesive have elastic properties andbe used sparingly. As identified above, if adhesive bonding techniquesare used or applied, the use of an adhesive having elastic properties,such as Findley HX 2695-01 adhesive, is generally preferred. Applicationof such adhesive might be desired in a location such as the crotchregion of an article and where urine might flow between the bond pointsof the outer cover, liner and containment flap attachment. Extended legcuffs 149 are also used so the outermost region of the leg cuffs 149 arenot affected by the outer cover or liner.

[0109]FIG. 8 shows the absorbent garment article 20 shown in FIG. 6 butnow showing bonding or attachment of the containment flap members,described above and which are not here themselves shown in an effort tosimplify illustration and facilitate comprehension. In particular, thecontainment flap members are secured by means of a combination of ultrasonic bonds 152 and elastic adhesive bonding 154 in the article orchassis perimeter area 130.

[0110] As will be appreciated by those skilled in the art and guided bythe teachings herein provided, the inclusion or use of such adhesivebonding may be desired in those embodiments wherein body exudate flowbetween ultra sonic bond points is of concern. Thus, application of suchadhesive may be limited to the area about the sonic bond points in thecrotch area of the particular absorbent garment article.

[0111] The independence of movement by or between components of theabsorbent articles in accordance with this aspect of the invention canprovide or result in significant product performance improvements. Forexample, as such an absorbent article is worn and becomes loaded withbody exudate, the absorbent materials contained therewithin are pushedoutward toward the outer cover. Meanwhile, the bodyside liner andcontainment flap members remain in close contact with the skin surfaceof the wearer. Skin health benefits are realized through minimizing oravoiding skin contact with the wet absorbent.

[0112] Further, whereas the components of absorbent articles havetraditionally been attached, adhered or secured to each other generallyover the entire areas thereof using adhesives, bonding and othertechniques such as to increase the overall stiffness of the absorbentarticle and reduce or eliminate independence of motion therebetween, theindependence of motion by or between components of the absorbentarticles in accordance with this aspect of the invention can provideimproved product fit and improve customer perceptions of such absorbentarticles.

[0113] Those skilled in the art and guided by the teachings hereinprovided will appreciate that the properties of the component materialscan be selectively manipulated such as to regulate or control productperformance, such as to regulate and control the relative movementbetween components. For example, tensions and configurations can beadjusted such that the absorbent material components fill or expanddownward toward the outer cover rather than upward toward the bodysideliner. Same or similar adjustments can be used to assist in maintainingthe bodyside components in close contact with the wearer during walkingor other leg movements. This has been demonstrated in clinical researchstudies, with a diaper loaded with 120 ml of synthetic urine, whereinthe containment flaps and liner stayed in contact with the body, whilethe outer cover expanded to allow for loading and the leg cuffs createda seal. In such a study, participants included infants weighing between16 and 28 lbs. In these tests of the study, the participants atdifferent times each wore:

[0114] a) a commercial HUGGIES SUPREME diaper and

[0115] b) a diaper having the features of the present invention.

[0116] For each product, the diaper was applied and a photograph taken.The diaper was then loaded with 120 ml of saline solution. The childrenwere allowed to play for approximately 45 minutes and then the diaperwas rephotographed. (See also the description of FIGS. 11-25 providedherein.)

[0117] While the invention has been described above making specificreference to particular preferred embodiments wherein absorbent articlesare provided which desirably self-form seals at natural body hingepoints of a wearer and such can desirably provide improved or increasedindependence of the components thereof, those skilled in the art andguided by the teachings herein provided will appreciate that theinvention can, if desired, be practiced making use of only certain orselected of the above-identified features. For example, the improved orincreased independence of the components realizable through theinvention can be utilized or applied in article design and manufacturewithout necessarily also incorporating a self-forming seal construction.Similarly, at least certain features of a self-forming seal absorbentarticle construction can be applied without also necessarily applyingthe features of improved or increased independence of articlecomponents.

[0118] In addition, at least some of the benefits associated withabsorbent articles such as described above and which desirably self-formseals at natural body hinge points of a wearer and improved or increasedindependence of the components can be realized by certain embodimentswhich include leg elastic members captured between article componentsand such as may also desirably simplify either or both manufacture andproduction as well as reduce the costs associated therewith.

[0119]FIGS. 9 and 10 illustrate a disposable absorbent article 160 inaccordance with one such preferred alternative embodiment of theinvention. The absorbent article 160, similar to the absorbent articlegarment 20 described above, has the general form of a disposable diapersuch as adapted to be worn about the lower torso by an infant. It is tobe understood and appreciated, however, that such an embodiment cansimilarly be applied to other forms or types of absorbent articlesincluding various disposable absorbent articles such as are generallyconfigured to collect and contain human discharges or exudates such as,including, urine and fecal material and which articles also desirablyavoid leakage of such discharge materials.

[0120] The diaper absorbent article 160 generally includes a chassis 162and further includes or defines a front waist area 164 forming a frontedge 166, a back waist area 170 forming a back edge 172, and a crotcharea 174 disposed between the front and back waist areas, 164 and 170,respectively. The front waist area 164 includes the portion of thediaper 160 which, when worn, is positioned on the front of the wearerwhile the back waist area 170 includes the portion of the diaper 160which, when worn, is positioned on the back of the wearer. The crotcharea 174 includes that portion of the diaper 160 which, when worn, ispositioned between the legs of the wearer and covers the lower torso ofthe wearer. The diaper absorbent article 160 forms or includes an innersurface 176 which is configured to contact the wearer, and an outersurface 180 opposite the inner surface 176 and such as configured tocontact the wearer's clothing.

[0121] For ease of reference, FIGS. 9 and 10 each include arrows 182 and184 depicting the orientation of the longitudinal and the lateral ortransverse axis, respectively, for the diaper absorbent article 160.Thus, the chassis 162 has opposed longitudinal sides 186 and 190,respectively, and opposed lateral sides 192 and 194, respectively. Inthe diaper absorbent article 160 each of the longitudinal sides 186 and190 and each of the lateral sides 192 and 194 is preferably straight. Aswill be appreciated by those skilled in the art and guided by theteachings herein provided the utilization of such a straight-sidedconstruction will typically facilitate manufacture and minimize orreduce scrap losses as such constructions can more practically berealized and repeatedly produced, as typically desired in large scalemanufacture and production.

[0122] The diaper absorbent garment article 160 and, specifically, thechassis 162 includes a biaxially extensible outer cover 196 such asserves, at least in part, to form the outer surface 180, and a biaxiallyextensible bodyside liner 200 such as serves, at least in part, to formthe inner or wearer adjacent surface 176. The outer cover 196 forms orincludes a cover perimeter 202. The bodyside liner 200 similarly formsor includes a liner perimeter 204. The outer cover 196 and the bodysideliner 200 are joined or connected, such as described in greater detailbelow, in a superposed relation. An absorbent core assembly, such asdescribed above or, alternatively, such as known in the art, isinterposed or otherwise located between the outer cover 196 and thebodyside liner 200.

[0123] In the illustrated embodiment, a non-curved or essentiallystraight leg elastic member 206 is captured between the biaxiallyextensible outer cover 196 and the biaxially extensible bodyside liner200 at least along the chassis longitudinal side 186. Similarly, anon-curved or essentially straight leg elastic member 210 is capturedbetween the biaxially extensible outer cover 196 and the biaxiallyextensible bodyside liner 200 at least along the chassis longitudinalside 190.

[0124] In accordance with a preferred embodiment of this aspect of theinvention, either or preferably both of the leg elastic members isformed of an elastic film material such as composed of Findley HX 2695Elastic Barrier Adhesive (EBA) and such as generally consists of apolymeric composition of white mineral oil, hydrogenated alpha-methylstyrene/styrene resin, styrene-isoprene block copolymer, and aromaticpetroleum hydrocarbon resin. In particular, it will be appreciated thatin such embodiments wherein the outer cover 196 and the bodyside liner200 are each at least biaxially extensible, the capture of suchnon-curved or essentially straight leg elastic members therebetweendesirably results in leg elastics that provide biaxial stretch withoutincurring the manufacturing and production complications associated withconventional curved leg elastics.

[0125] As will be appreciated, by completely enclosing such an elasticfilm material between the outer cover 196 and the bodyside liner 200 toprovide areas of elasticity in the leg opening regions of an absorbentarticle, a more refined, uniform appearance can be achieved such thatthe absorbent article has a more pant-like form as the absorbent articledesirably no longer includes leg elastic extending from the legopenings.

[0126] Further, by eliminating the layer of independent leg elastic andby eliminating the ultrasonic bonds needed to bond the elastic to theabsorbent article chassis, an absorbent article in accordance with theembodiment of the invention provides better conformance to the movementand body shape of the user. The fit and comfort of the absorbent articleof the invention are also improved by the more uniform distribution offorce in the leg openings provided by a planar elastic material.Conventional stranded elastic present in leg elastic materials causesmore localized and intense pressure on the areas of the skin of thewearer with which the elastic comes into contact. By completelyenclosing an elastic film material between an outer cover and a bodysideliner to provide areas of elasticity in the leg openings of an absorbentarticle, a more refined, uniform appearance is achieved; the articlelooks more “underwear-like” as, for example, it no longer has legelastic extending from the leg openings.

[0127] Further, the diaper absorbent garment article 160 can desirablyproduce, supply or otherwise results in self-forming seals, such asdescribed herein.

[0128] The diaper absorbent garment article 160 may additionally includea fastening system 220 and waist elastics 222 and 224, as are known inthe art.

[0129] In addition, from a process standpoint, the in-captured legelastic of this embodiment of the invention provides several advantages.Conventional elastics provide machine direction stretch but not crossdirection stretch. Even EBA, in its presently available form of having afacing, only achieves machine direction stretch. Consequently, currentabsorbent article processes require the leg elastic portion to be curvedsuch that the leg elastic portion is curved around the chassis toreverse the stretch of the uni-directional elastic. Curving is necessaryto provide machine direction stretch in the crotch portion and crossdirection stretch in the upper thigh and hip portion of the absorbentarticle. In addition, incorporation and use of conventional extended legelastics necessitate additional processing steps that could beeliminated by the use of the in-captured leg elastic of the invention.With extended leg elastics, the leg openings must be water-cut twice:(1) chassis is water cut to form the leg opening area between the outercover and the bodyside liner, and (2) leg elastic material must be watercut to give desired contour. Thus, the current process has many andvarious challenges associated with using an extended leg elastic. Forexample, the extended leg elastic must be kept in place between theouter cover and bodyside liner during water cutting; this registrationbetween the leg elastic and the outer cover/bodyside liner is verydifficult to maintain. Bonding apparatus must be properly registered toform the seam between the extended leg elastic and the outercover/bodyside liner combination. The additional water-cutting,registration and bonding steps of such a conventional process increasethe potential for product defect. These processing steps can desirablybe eliminated by using the in-captured leg elastic process of theinvention.

[0130] To enhance an understanding and appreciation of the invention andthe advantages and benefits attendant thereto reference will now be madeto FIGS. 11, 13, 15, 17, 19 and 21-25 which depict an absorbent garmentarticle in accordance with the embodiment of the invention heredesignated by the reference numeral 300, shown in FIGS. 1 and 2 anddescribed above, and FIGS. 12, 14, 16, 18 and 20 which depict a priorart absorbent garment article, designated by the reference numeral 400.

[0131] In particular, in FIGS. 11, 13 and 19, the absorbent garmentarticle 300 is shown as including front self-forming seals, designatedby the reference numerals 302 and 304, respectively, and rearself-forming seals, designated by the reference numerals 306 and 308,respectively, such as the natural hinge points of a body such as at thejunction between the body torso and the leg. As shown, the absorbentgarment article 300 provides a closer fit unto the skin of the wearer.Further, the absorbent garment article 300 provides a more refined,uniform pant-like appearance, such as may be desired for diaper typeabsorbent garment articles. That is, the absorbent garment article 300can create a fit similar to or corresponding to that such as cannormally be realized with underwear.

[0132] The improved fit, appearance and containment capabilities of thesubject absorbent garment article shown in FIGS. 11, 13, 15, 17 and 19,as compared to the prior art absorbent garment article correspondinglyshown in FIGS. 12, 14, 16, 18 and 20, is evident. Further, FIGS. 21-25show that such improved fit, appearance and containment capabilitiescontinue even after loading and wear as these figures show noappreciable change in appearance of the absorbent garment article 300 asworn on the torso even after loading and wear.

[0133] FIGS. 11-15 are drawings rendered based on the photographs takenas part of the previously described research study.

[0134] In comparing the fit of the articles illustrated in FIGS. 11 and12, the article depicted in FIG. 12 shows tension and bunching of thediaper materials. Further, tension on the diaper has caused the frontwaist to droop. With articles of the invention, as depicted in FIG. 11,the independence of the components allows the tension experienced by thediaper components to be dissipated and distributed throughout the wholearticle as opposed to just the fasteners. The construction of thearticles of the invention relieves the stress experienced by thematerials in use. Conventional diapers are oversized to accommodate thetension and forces experienced in use. The elastic properties of thematerials used in the articles of the invention permit the tension andforces to be absorbed without compromising the fit of the article.

[0135] In comparing the fit of the articles as viewed in FIGS. 13 and14, the waist of the article in FIG. 14 is flipped over. The rearportion of the article in FIG. 14 is collapsed down and is bunched up.Further, the article in FIG. 14 has no defined leg gasket. The articleof FIG. 13, representing an article of the invention, has defined sealsaround the leg and the waist. When the leg elastics of the articles arepulled back as illustrated in FIGS. 15 and 16, the article of theinvention maintains its seal around the leg. With the conventionaldiaper illustrated in FIG. 16, the gasket is undefined; such as to notpermit a determination of whether the material is from the containmentflap or the liner. FIGS. 17 and 18 show the fit of the articles when theleg of the wearer is lifted high. The conventional diaper experiencessignificant bunching and the article tries to contort with the movementof the wearer. No such bunching is experienced by the article of theinvention depicted in FIG. 17. The back view of an article of theinvention depicted in FIG. 19 shows the self-forming seal that formsaround the legs of the wearer. As previously described, FIGS. 21-25illustrate that the fit of the articles of the invention is notnegatively impacted when the article becomes loaded.

[0136] In view of the above, absorbent article configurations andconstructions in accordance with the invention desirably provideimprovements with respect to at least one, preferably at least two and,more preferably all three of the absorbent article qualities orproperties of fit, comfort and containment capability for body fluidsand exudates. As detailed below, absorbent articles, in accordance withat least certain preferred embodiments of the invention, involve theselection and use of certain specified materials in certain specificabsorbent article constructions.

[0137] In accordance with at least certain aspects described above, thepresent invention provides an improved absorbent article which desirablyself-forms seals at natural body hinge points of a wearer.

[0138] In accordance with another aspect of the invention, there isprovided absorbent articles which generally desirably provide or resultin improved or increased independence of the components thereof.

[0139] In accordance with yet another aspect of the invention, there isprovided absorbent articles of specific construction and which includecaptured leg elastics such as may desirably simplify either or bothmanufacture and production and the costs associated therewith.

[0140] Those skilled in the art and guided by the teachings hereinprovided will appreciate that the self-forming seals and productadvantages realized through the practice of the invention, such asimproved fit, appearance and containment capabilities, for example, arebelieved due to one or more contributing factors such as includingbiaxial extensibility/stretch, diagonal extensibility/stretch,independence of components, asymmetric shape and avoidance orminimization of bonding, particularly in the interior area of thechassis, for example.

[0141] The invention illustratively disclosed herein suitably may bepracticed in the absence of any element, part, step, component, oringredient which is not specifically disclosed herein.

[0142] While in the foregoing detailed description this invention hasbeen described in relation to certain preferred embodiments thereof, andmany details have been set forth for purposes of illustration, it willbe apparent to those skilled in the art that the invention issusceptible to additional embodiments and that certain of the detailsdescribed herein can be varied considerably without departing from thebasic principles of the invention.

What is claimed is:
 1. An absorbent article adapted to be worn by awearer, the absorbent article including a front waist area forming afront edge, a back waist area forming a back edge, and a crotch areadisposed between the front and back waist areas, the absorbent articlecomprising: a chassis having opposed first and second longitudinal sidesand opposed first and second lateral sides, the chassis having anoriginal longitudinal length and an original lateral length, the chassisdefining first and second leg openings and including; a biaxiallyextensible outer cover, a biaxially extensible bodyside liner forming awearer adjacent surface, an absorbent core assembly interposed betweenthe biaxially extensible outer cover and the biaxially extensiblebodyside liner, a first leg elastic member captured between thebiaxially extensible outer cover and the biaxially extensible bodysideliner along the first longitudinal side of the chassis and a second legelastic member captured between the biaxially extensible outer cover andthe biaxially extensible bodyside liner along the second longitudinalside of the chassis.
 2. The absorbent article of claim 1 wherein atleast one of the first and second longitudinal sides of the chassis is astraight edge.
 3. The absorbent article of claim 2 wherein each of thefirst and second longitudinal sides of the chassis is a straight edge.4. The absorbent article of claim 1 wherein the at least one of thefirst and second leg elastic members comprises an elastic film material.5. The absorbent article of claim 4 wherein each of the first and secondleg elastic members comprises an elastic film material.
 6. The absorbentarticle of claim 4 wherein the elastic film material comprises apolymeric composition including white mineral oil, hydrogenatedalpha-methyl styrene/styrene resin, styrene-isoprene block copolymer,and aromatic petroleum hydrocarbon resin.
 7. The absorbent article ofclaim 1 wherein the chassis can be longitudinally extended at least 5percent of its original longitudinal length.
 8. The absorbent article ofclaim 1 wherein the chassis can be longitudinally extended at least 15percent of its original longitudinal length.
 9. The absorbent article ofclaim 1 wherein the chassis can be longitudinally extended at least 30percent of its original longitudinal length.
 10. The absorbent articleof claim 1 wherein the chassis can be longitudinally extended up to 150percent of its original longitudinal length.
 11. The absorbent articleof claim 1 wherein the chassis can be longitudinally extended up to 125percent of its original longitudinal length.
 12. The absorbent articleof claim 1 wherein the chassis can be longitudinally extended up to 100percent of its original longitudinal length.
 13. The absorbent articleof claim 1 wherein the chassis can be laterally extended at least 10percent of its original lateral length.
 14. The absorbent article ofclaim 1 wherein the chassis can be laterally extended at least 25percent of its original lateral length.
 15. The absorbent article ofclaim 1 wherein the chassis can be laterally extended at least 50percent of its original lateral length.
 16. The absorbent article ofclaim 1 wherein the chassis can be laterally extended up to 200 percentof its original lateral length.
 17. The absorbent article of claim 1wherein the chassis can be laterally extended up to 150 percent of itsoriginal lateral length.
 18. The absorbent article of claim 1 whereinthe chassis can be laterally extended up to 125 percent of its originallateral length.
 19. The absorbent article of claim 1 wherein the chassiscan be diagonally extended at least 10 percent of its original diagonallength.
 20. The absorbent article of claim 1 wherein the chassis can bediagonally extended at least 25 percent of its original diagonal length.21. The absorbent article of claim 1 wherein the chassis can bediagonally extended at least 50 percent of its original diagonal length.22. The absorbent article of claim 1 wherein the chassis can bediagonally extended up to 200 percent of its original diagonal length.23. The absorbent article of claim 1 wherein the chassis can bediagonally extended up to 150 percent of its original diagonal length.24. The absorbent article of claim 1 wherein the chassis can bediagonally extended up to 125 percent of its original diagonal length.25. The absorbent article of claim 1 wherein the biaxially extensibleouter cover comprises a polypropylene spunbond that is laminated withstyrene-isoprene-styrene-based adhesive.
 26. The absorbent article ofclaim 1 wherein the biaxially extensible bodyside liner comprises asurfactant-treated polypropylene spunbond, necked and creped at about50%.
 27. The absorbent article of claim 1 comprising a diaper.
 28. Theabsorbent article of claim 1 comprising a swim wear garment.
 29. Theabsorbent article of claim 1 comprising a training pants.
 30. Theabsorbent article of claim 1 comprising an adult incontinence garment.31. An absorbent article adapted to be worn by a wearer, the absorbentarticle including a front waist area forming a front edge, a back waistarea forming a back edge, and a crotch area disposed between the frontand back waist areas, the absorbent article comprising: a chassis havingopposed first and second longitudinal sides and opposed first and secondlateral sides, each of the first and second longitudinal sides forms astraight edge, the chassis having an original longitudinal length and anoriginal lateral length, the chassis defining first and second legopenings and including; a biaxially extensible outer cover, a biaxiallyextensible bodyside liner forming a wearer adjacent surface, anabsorbent core assembly interposed between the biaxially extensibleouter cover and the biaxially extensible bodyside liner, a first legelastic member captured between the biaxially extensible outer cover andthe biaxially extensible bodyside liner along the first longitudinalside of the chassis and a second leg elastic member captured between thebiaxially extensible outer cover and the biaxially extensible bodysideliner along the second longitudinal side of the chassis, wherein atleast one of the first and second leg elastic members comprises anelastic film material.
 32. The absorbent article of claim 31 whereineach of the first and second leg elastic members comprises an elasticfilm material.
 33. The absorbent article of claim 31 wherein the elasticfilm material comprises a polymeric composition including white mineraloil, hydrogenated alpha-methyl styrene/styrene resin, styrene-isopreneblock copolymer, and aromatic petroleum hydrocarbon resin.
 34. Theabsorbent article of claim 31 wherein the chassis can be longitudinallyextended at least 5 percent and up to 150 percent of its originallongitudinal length; laterally extended at least 10 percent and up to200 percent of its original lateral length; and diagonally extended atleast 10 percent and up to 200 percent of its original diagonal length.35. The absorbent article of claim 31 comprising a diaper.
 36. Theabsorbent article of claim 31 comprising a swim wear garment.
 37. Theabsorbent article of claim 31 comprising training pants.
 38. Theabsorbent article of claim 31 comprising an adult incontinence garment.